Home

maintenance

1. A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm OD RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your Polaris dealer knows your
2. 113 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 114
3. Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low batterv voltage Recharge the batterv to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See vour dealer Overheated engine Clean radiator screen and core clean engine exterior see vour dealer 104 DECLARATION OF CONFORMITY We Polaris Industries Inc declare that the vehicles listed below conform to the Polaris Industries Inc C E essential health and safety requirements applicable to off road all terrain vehicles 2100 Hwy 55 Medina MN 55340 U S A APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS Telephone 763 542 0500 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 EN 55012 2002 Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 CAN CSA C108 4 M92 EN 61000 6 2
4. Place shop towels under the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing sur face on the engine Lubricate the gasket on the new filter with a film of new engine oil Make sure the gasket is in good condition Make sure the gasket from the old filter is not still on the engine Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 ft lbs 19 Nm Remove the dipstick Add two quarts 1 9 1 of recommended oil If the sump is not drained add about 1 3 4 quarts 1 6 1 initially Reinstall the dipstick Prime the oil pump using the procedure on page 58 Then stop the engine and inspect for leaks Check the oil level on the dipstick Add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 57 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1
5. Press the top of the switch to engage All Wheel Drive AWD See page 45 for AWD operating instructions Move the switch to the center position to lock the differential and operate in two wheel drive Ignition Switch Choke 2WD Press the bottom of the Light Switch Knob switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed See page 46 for Differential Lock operating instructions 21 FEATURES AND CONTROLS Gear Selector H High Gear Gear Selector L Low Gear N Neutral R Reverse P Park Low gear is the primary driv ing range for the RANGER High gear is intended for use on hard packed surfaces with light loads Whenever the vehicle is left unattended always place the transmission in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmis sion function See your dealer if you experience any shifting problems NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle 22 FEATURES AND CONTROLS Brake Pedal Depress
6. Pantone 426C RANGER 400 HO Owner s Manual for Maintenance and Safety Pantone 426C AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate e At speeds too fast for vour skills or the conditions e After or while using Alcohol or Drugs e On hills steeper than 15 degrees 15 e On public roads A collision can occur with another vehicle e With more than ONE passenger or with a passenger under age twelve or who cannot comfortablv reach the floor and hand holds e On paved surfaces pavement may seriously affect handling and control e With non Polaris approved accessories they may seriously affect stability ALWAYS e Wear your seat belt Vehicle rollover could cause severe injury or death e Wear a helmet and eye protection and keep hands and feet in vehicle at all times e Reduce speed and use extra caution when carrying passengers e Avoid sharp turns or turns while applying heavy throttle e Operate slowly in reverse avoid sharp turns or sudden braking e Make sure passenger reads and understands all safety labels Watch for branches or other hazards that could enter vehicle READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer PE LARIS call 1 800 POLARIS neay out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922123 Rev 03 Printed in USA
7. This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in ord
8. Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the iss gt Pressure vent line s pressure relief slit Relief Slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation Tip If you do not hear air the line has not bled Repeat the priming procedure 58 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 43 6 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic 1290 ml 19 4 Nm 19 4 Nm Gearcase Lube Front Gearcase Premium Demand 9 3 oz 8 10 ft Ibs 11 ft Ibs Drive Hub Fluid 275 ml 11 13 6 Nm 15 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 100 for the part numbers of Polaris products Oil Check The fill plug is located at the rear of the vehicle Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil leve
9. Strut w 8 in 20 3 cm of travel Rear Suspension Independent w 9 in 23 cm of travel 98 SPECIFICATIONS RANGER 400 HO Driving System Type PVT Shift Type Single Lever console Gear Reduction Low 7 70 1 Gear Reduction Reverse 7 00 1 Gear Reduction High 4 12 1 Drive Ratio Front 3 818 1 Tire Size Front 25x 8 12 Tire Size Rear 25x 11 12 Tire Pressure Front 10 psi 68 9 kPa Tire Pressure Rear 10 psi 68 9 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Indicator Light 1 0 W Clutching See your Polaris dealer for clutching specifications 99 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 02 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 02 2872277 Premium Demand Drive Hub Fluid 2
10. move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and fol low the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 15 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to pre vent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 12 SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these pur poses Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris RANGER is terminated if any equipment has
11. 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAIVE MODEL SOUND YEARS PRESSURE dB A KAOS OUTLAW 50 2008 2009 2010 76 8 KA00 OUTLAW 90 2008 2009 2010 76 8 FA09 SPORTSMAN 90 2008 2009 2010 76 8 __VAI7__ RZR 170 2009 2010 81 3 ___PB20__ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 CA32 TRAIL BOSS 330 2008 2009 2010 76 8 BASO SCRAMBLER 500 2008 2009 2010 79 6 GJA5S OUTLAW 450 2008 2009 2010 80 7 GJ52__ __GP52 OUTLAW 525 2008 2009 2010 80 7 __LH27__ SPORTSMAN 300 2008 2009 2010 81 1 __LH46__ SPORTSMAN 400 2008 2009 2010 80 2 MN5O SPORTSMAN 500 EFI 2008 2009 2010 80 4 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 DN55 SPORTSMAN X2 TOURING 550 2010 77 2 MNI6 SPORTSMAN 800 2008 2009 2010 83 6 TN85 DNS85 SPORTSMAN X2 TOURING 850 2010 77 2 CL76 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85 ZXS85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HH76 RANGER 800 EFI 4X4 2010 76 5 ___WH76__ RANGER 800 EFI CREW 2010 76 5 __HR__ RANGER 800 6X6 2010 76 5 __HY__ RANGER HD 800 4X4 2010 76 5 VH76 RANGER RZR 2008 2009 2010 85 8 Authorized Signatory 2 P t 4 Fe v 105 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris RANGER against defects in mate rial or workmanship Polaris also gives a
12. 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 2872893 Engine Degreaser 12 oz 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 100 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range See warnings on page 34 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequentiv See page 68 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easv clutch engage ment Use the throttle quickly and effectively Towi
13. 500 hours of engine operation 5000 kilo meters 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables FuelLine Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evapora
14. EQ E flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RANGER 5 After leaving water always dry the brakes by applying light pres sure to the pedal repeatedly until braking action is normal NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 48 Give special attention to engine oil transmission oil front and rear gearcases if equipped and all grease fittings 36 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 Alwavs check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantiv alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 37 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles 9v Ue pos B Never open the throttle sudden
15. Selector Storage Lights Shifter Compartment Storage 12V Auxiliary Cup Tray Outlets Holder Auxiliary Outlets The 12 volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Indicator Lights High Reverse Temperature SIRE Low Gear X X Y f V X S LIPIR S y Park Gear Neutral Gear High Gear 20 FEATURES AND CONTROLS Switches Ignition Switch Light Switch The ignition switch is a four position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V LIGHTS ON Lights are on Electrical circuits are on Electrical equip ment can be used LIGHTS OFF Lights are off Electrical circuits are on Electrical equip ment can be used START Turn the key to the START position to engage the electric starter Turn the key to the LIGHTS ON position after start ing the engine AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel rE ien Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1WD Turf Mode
16. as needed E Toe adjustment Inspect periodically adjust when parts are replaced W Auxiliary brake if Inspect daily adjust as gt equipped needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services 52 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 48 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 PLUS Performance See page 55 Synthetic 2W 50 Brake Fluid DOT 4 See page 78 Main Gearcase Oil Premium AGL Synthetic See page 59 Transmission Gearcase Lube Front Gearcase Oil Premium Demand Drive Hub See page 61 Fluid Front Prop Shaft Yoke Polaris Premium U Joint Locate fittings and grease Lube 3 pumps maximum GI 1A Prop Shaft U Joint 53 Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in en
17. check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Always check the pedal for free movement and return before starting the engine and occasionally during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Throttle Freeplay If the throttle pedal has excessive a play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Adjust the freeplay if necessary Throttle Pedal Throttle Freeplay Inspection 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm 76 MAINTENANCE Throttle System Throttle Freeplay Adjustment 1 2 3 Tip Remove the seat Locate the throttle cable adjuster Squeeze the end of the rub ber boot and slide it far enough to expose the end of t
18. corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 111 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 112 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS
19. during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts 10 SAFETY Operator Safety Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at exces sive speeds Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedur
20. fuel pump wires Attempt to start the engine If necessary repeat the drying proce dure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 69 for drying MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Service the air filter more fre quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 2 Tip Lift the cargo box to access the air box WN a Remove the air box Air Filter ey P ia cover and inspect the CM Y Yo gasket It should adhere tightly to the cover and seal all the way around Remove the air filter Do not attempt to clean the main element Install a new air filter Apply a small amount of APTUM general purpose grease to ee N HI the sealing edges of the M y oL filter before installing s T o Inspect the air box for oil or water deposits If present drain them into a suitable container Fuel Filter Your Polaris vehicle is equipped with an in line fuel filter Have your dealer replace it after every 100 hours of operation Do not attempt to clean the fuel filter 71 MAINTENANCE Filter Systems Breather Filter and Hoses 1 Lift the cargo box and locate the air box 2 Follow the right h
21. if equipped gt Middle Gearcase 25H Monthly Inspect level change yearly Oil if equipped gt Rear gearcase oil 25H Monthly Inspect level change yearly if equipped gt Transmission oil 25H Monthly Inspect level change yearly gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services 50 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine breather 25H Monthly Inspect replace if necessary E filter if equipped gt Engine oil change 25H 1M x Perform a break in oil change break in at one month gt General 50H 3M Lubricate all fittings pivots lubrication cables etc Shift Linkage 50 H 6M Inspect lubricate adjust E Steering 50H 6M Lubricate gt Front Suspension 50H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate Carburetor float 50 H 6M Drain bowl periodically and bowl prior to storage W Throttle cable 50 H 6M Inspect adjust lubricate E replace if necessary E Choke cable 50 H 6M Inspect adjust lubricate E replace if necessary E Carburetor air 50 H 6M Inspect ducts for proper seal intake ducts flange ing air leaks Drive belt 50 H 6M Inspect adjust replace as needed Cooling system 50
22. key when the engine starts Turn the key to the LIGHTS ON position before driving Do not press the throttle pedal while starting the engine If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 7 and 8 until the engine starts Choke Knob FULL ON HALF ON OFF 2RE OPERATION Starting the Engine 9 Ifa warm engine has cooled to a point where it does not readily start intermittent use of the choke half way out may be necessary If the engine is over choked when warm depress the throttle pedal fully while cranking to aid in starting Release the throttle pedal immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 10 After the engine starts push the choke knob in half way 11 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly 12 Push the choke knob in NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmission in PARK 3 Turn the engine off WARNING A rolling vehicle can cause serious injury Always place the transmission in PARK when stopping the engine Braking 1 Release the throttle pedal co
23. little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery Tip If accessories are using power constantly while the vehicle is operated in colder temperatures below 30 F 1 C a 30 amp hour battery will pro vide the best performance including improved starting performance 86 MAINTENANCE Battery Battery Removal A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the seat 2 Onconventional batteries remove the battery vent tube 3 Disconnect the black battery cable first 4 Disconnect the red battery cable last 5 Lift the battery out of the vehi cle Be careful not to tip a con ventional battery sideways Battery which could
24. proper operation GA Brake fluid Ensure proper level 78 Park gear Ensure vehicle does not roll when in PARK Ensure PARK light illuminates Front suspension Inspect lubricate if necessary 53 Rear suspension Inspect lubricate if necessary 53 Steering Ensure free operation 79 Tires Inspect condition and pressure TA Wheels fasteners Inspect ensure fastener tightness 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 89 Coolant level Ensure proper level BS Coolant hoses Inspect for leaks Throttle Ensure proper operation 76 Indicator lights switches Ensure operation 20 Air filter pre filter Inspect clean 71 Air box sediment tube Drain deposits whenever visible 71 Headlamp Check operation apply Polaris dielec 83 tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 85 tric grease when lamp is replaced Seat Belts 25 29 OPERATION Starting the Engine 1 A Lope 9 30 Always start the engine outdoors or in a well ventilated area Turn the fuel valve on Sit in the driver s seat and fasten the seat belt Apply the brakes Place the transmission in PARK Do not use the choke if starting a warm engine Excessive use of the choke can cause spark plugs to become wet fouled If the engine is cold pull the choke knob out until it stops Turn the ignition key to START Engage the starter for a maxi mum of five seconds Release the
25. spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 87 MAINTENANCE Battery Battery Installation NOTICE Using a new battery that has not been fully charged can damage the NOTICE Route the vent tube as SOOO SOON ecA 88 battery and result in a shorter life It can also hinder vehicle performance Always install a fully charged battery Ensure that the battery is fully charged Place the battery in the battery holder Make sure the positive terminal is toward the passenger side of the vehicle Install the battery vent tube and route it down in front of the shift cable into the left front wheel well Route the vent tube through the hole in the frame support from the back side and place it behind the wheel well panel shown to prevent electrolyte from damaging critical components such as the wire harness brake lines and throttle cable Coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables are properly routed Install the hold down strap MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun
26. the front of the seat and slide it toward the front of the vehi cle Install the seat by sliding the tabs into the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets Fuel Cap The fuel tank filler cap is located on the right hand side of the vehi cle near the passenger seat When refueling always use either leaded or unleaded gasoline with a mini mum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel 26 OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new Polaris RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following pro cedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use 27 OPERATION Break I
27. the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the frame under the seat Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 47 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace p
28. to cool before servicing p 2 Unplug the headlamp o from the wiring harness n i Wiring Harness i gi Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly 83 MAINTENANCE Lights Headlight Beam Adjustment 84 Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Start the engine Turn on the headlights Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step If a headlight needs adjustment access the adjustment screw under the hood or through the wheel well Loosen the screw adjust the headlight and tighten the screw Repeat steps 4 6 until the lamp is properly adjusted MAINTENANCE Lights Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should c
29. 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m Stop completely Shift into low gear and drive forward DY GS If the front gearcase remains locked after following these instruc tions return the vehicle to your dealer for service 45 OPERATION All Wheel Drive AWD Locking the Differential NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential Locking the differential in slippery or low traction conditions helps improve 4 gt traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate indepen dently This mode of operation is well suited to turf driving or whenever aggressive traction is not required 46 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrestor be installed and functional when
30. Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of USFS standard 5100 1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 108 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions
31. ES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 107 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing
32. H 6M z Inspect coolant strength if applicable seasonally pressure test System yearly gt Engine oil change 100 H 6M 2 Perform a break in oil change at one month gt Oil filter change 100 H 6M Replace with oil change gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services 51 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Fuel system 100 H 12M Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years E Fuel filter 100 H 12M Replace yearly gt Radiator 100 H 12M l Inspect clean external in applicable surfaces gt Cooling Hoses 100H 12M Inspect for leaks gt Engine mounts 100 H 12M Inspect Exhaust muffler 100 H 12M Inspect pipe gt Spark plug 100 H 12M Inspect replace as needed E E Ignition timing 100 H 12M Inspect gt Wiring 100 H 12M Inspect for wear routing securitv applv dielectric grease to connectors subjected to water mud etc E Clutches drive 100H 12M Inspect clean replace worn and driven parts E Front wheel 100 H 12M Inspect replace as needed bearings E Brake fluid 200 H 24M 2 Change every two years Spark arrestor 300 H 36 M Clean out Idle speed Adjust
33. Reinstall the cap 4 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil 5 Treat the fuel system with Polaris Carbon Clean See page 95 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline 6 To eliminate any fuel remaining in the carburetor run the engine until it stops Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a gen uine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 96 MAINTENANCE Removal from Storage 1 pa Check the battery electrolyte level and charge the battery if neces sary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 29 Tightness of the bolts nuts and other fasteners should be checked by an authorized Polaris dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Transporting the RANGER Follow these procedures when transporting the vehicle A DXX Apply the brakes Place the transmission i
34. and breather line out the side of the air box and locate the filter 3 Remove and inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clog ging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine Secure the clamps NOTICE Operation of the vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 72 MAINTENANCE Carburetor The idle speed adjustment should be performed as outlined in the Peri odic Maintenance Chart or whenever the idle speed is changed Recom mended engine idle RPM is 1200 200 Carburetor Engine Idle RPM Adjustment If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted 1 Apply the brakes 2 Place the transmission in PARK 3 Start the engine and allow it to warm up for approximately five minutes 4 Remove the seat Locate the idle adjust Screw 5 Place the transmission in gear 6 Turn the screw in clockwise to raise RPM Turn the screw out counter clockwise to lower RPM Idle Adjust Screw 73 MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service o
35. arts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 112 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oll level and if it continues to rise discontinue use and determine the cause or see your dealer 48 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions B6 Have an authorize
36. ase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to spec ification Oil Change PING 1 Support the vehicle securely with a jackstand 2 ee the front tire on the driver s Drain Plug side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Remove the drain plug Drain the oil 6 Clean the drain plug Reinstall the drain plug Torque to specifica tion 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 61 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 98 for the recom mended spark plug type for your vehicle Always torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark Plug Gap Torque Model Electrode Gap New Plug Used Plug Torque Torque RANGER 400 036 9 mm 9 11 ft Ibs 9 11 ft Ibs HO 12 15 Nm 12 15 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for co
37. ash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and your passengers skills 15 SAFETY Operator Safety Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or s
38. been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 13 SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride asa passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Seat Belts Riding in thi
39. bon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Drain the carburetor bowl Cil and Filter Change the oil and filter See page 56 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 71 2 Clean the air box 3 Drain the sediment tube Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 48 Battery Maintenance See pages 89 91 for storage and charging procedures 95 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 48 Front and rear gearcase fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Remove the spark plug and add 2 3 tablespoons 30 45 ml of engine oil 2 Reinstall the spark plug Torque to specification See page 62 3 Apply dielectric grease to the inside of the spark plug cap
40. d Polaris dealer perform these services WARNING Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 49 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre Ride Make adjustments as need n ed See Pre Ride Checklist gt Front suspension Pre Ride on page 29 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level E Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible E tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly Inspect periodically u Battery 20H Monthly Check terminals clean test gt Front Gearcase Oil 25H Monthly Inspect level change yearly
41. d cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying a passenger Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passenger reads and understands all safety labels Watch for branches or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176169 SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully Follow the operating procedures described Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds The driver and any passenger must wear helmet eye protection and seat belt at all times Always keep arms and legs inside the cab frame while the vehicle is in motion Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle
42. d or reused cloths and pads may contain dirt particles that will scratch the finish 92 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items Wheel bearings e Radiator Transmission seals Brakes Cab and body panels Labels and decals Switches and controls Hlectrical components and wiring If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 93 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels
43. e shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft Ibs 40 Nm Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjust ment cam either clockwise or counter clockwise to increase or decrease spring tension Rear Suspension Shown Adjustment is similar for Front Suspension 80 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less 27 SS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Y Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 90 ft lbs 122 Nm 2 Piece Flange Aa Front and Rear 35 ft Ibs 47 Nm Nut O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm 81 MAINTENANCE Tires Wheel Removal 1 Apply the brakes 2 Place the transmission
44. ean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 48 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 67 MAINTENANCE Polaris Variable Transmission PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance cr
45. eating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation When To Use Low Range vs High Range Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High 68 MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys tem Use the following instructions to dry it out before operating 1 2 Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Rein stall t
46. ections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Water is present in fuel Drain the fuel svstem and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessarv No spark to spark plug Inspect plugs and replace if necessarv Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plug Low battery voltage Mechanical failure Recharge the battery to 12 8 VDC See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See vour dealer Incorrect ignition timing See vour dealer Mechanical failure See vour dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 102 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor qualitv or low octane fuel Solution Replace with recomm
47. ended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Other mechanical failure Possible Lean Fuel Cause Overuse of choke Inspect and clean or replace See vour dealer Solution Inspect clean and or replace spark plug Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Possible Rich Fuel Cause Fuel is very high octane Solution Replace with lower octane fuel 103 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect clean and or replace spark plug Water is present in fuel Replace with new fuel
48. er 24 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pulleach seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized Polaris dealer 4 Toclean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household deter gents 25 FEATURES AND CONTROLS Roll Over Protection System ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 ee ends rollover performance require ments Always have your authorized Polaris dealer thor oughly inspect the ROPS if it ever becomes damaged in any way No device can assure occu pant protection in the event of a rollover Always follow all safe operating practices out lined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Seat Removal Pull up on
49. er to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 109 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of
50. eriodic Maintenance Chart beginning on page 48 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 65 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle is located in front of the right front wheel 1 Position the vehicle on a level surface 2 View the coolant level in the overflow bottle 3 Ifthe coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the cap and use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer Overflow Bottle Radiator Cap 66 MAINTENANCE Cooling System Radiator Coolant Level Always check and cl
51. es for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for trav eling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skid ding or sliding out of control 11 S AFETY Operator Safety Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stop ping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse
52. f the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label Container Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Load 500 Ibs 227 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT TIRE INFLATE TO 10 psi 68 9 kPa REAR TIRE INFLATE TO 10 psi 68 9 kPa MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO AND ACCESSORIES 1000 LBS 455 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information 7175941 SAFETY Safety Labels and Locations Age 16 Warning Discretionary Operating this yeni if you are Age 16 Warning under the age of 16 inc
53. filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for two to three minutes Stop the engine Screen Fitting 4 Clean the area around the oil tank drain plug 5 Place a drain pan under the oil tank CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 6 Removethe drain plug Allow the oil to drain completely 7 Install a new sealing washer on the drain plug The sealing Alignment Mark surfaces on drain plug and oil tank should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting Tip The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 10 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank Tip Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 11 Reattach the oil line 56 MAINTENANCE Engine Oil Oil and Filter Change 12 13 14 15 16 Tip 17 18 19 20 21 22
54. fore proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 90 Battery MAINTENANCE Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Action fak E Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None chec
55. from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 94 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 92 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Car
56. gine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 100 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 54 Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 See page 54 for oil recom mendations Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface Place the transmission in PARK 2 Start the engine and allow it to idle for 20 30 sec onds Stop the engine 3 Remove the seat See page 26 4 Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick Screw it in completely Remove the dipstick Make sure that the oil level is in the safe range Add oil if necessary Do not overfill Reinstall the dipstick MAINTENANCE Safe te ik Add E Ti 55 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and
57. h seat belt fastened securely 41 OPERATION Dumping the Cargo Box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes 3 Place the transmission in PARK 4 Dismount the vehicle 5 Ensure that the cargo is posi tioned evenly or toward the front of the cargo box Release Lever 6 Release the tailgate latches WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 7 Stand clear and pull up on the cargo box release lever 8 Liftthe front of the cargo box to dump the cargo 9 Lower the cargo box and push down securely to latch 10 Close the tailgate and secure both tailgate latches WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 42 Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability A
58. he drain plug Place the transmission in PARK Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 69 MAINTENANCE Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it fol low the steps outlined below 1 2 3 10 11 12 13 14 70 Move the vehicle to dry land or at the very least to water below the footrests Disconnect the fuel pump wires Remove the spark plug Place a clean container under the engine and loosen the carburetor drain screw two turns Dry any water present in the air box Filter replacement is required if water is present Thoroughly dry the air pre cleaner located under the hood Turn the engine over several times using the electric start Inspect the drained fuel for water or sediment Dry the spark plug and reinstall it or install a new plug Tighten the carburetor drain screw Reconnect the
59. he ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 17 FEATURES AND CONTROLS Component Locations ROPS Cab Frame Hip Bar Console Cargo Box Fuel Tank Cap ELA PELEMIS Headlights Radiator Front Bumper Brush Guard 18 FEATURES AND CONTROLS Component Locations Tailgate H Latch H Releases Tailgate o L e A Muffler Receiver Spark Arrestor 7 Hitch CV Boot Rear Caliper Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 40 43 19 FEATURES AND CONTROLS Console Indicator Gear
60. he inline cable adjuster Bdot Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle HOC NUR Adjuster pedal See page 76 While adjusting lightly flip the throttle pedal up and down Tighten the lock nut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Cylinder Head Cylinder Base Fastener Torque Have your dealer check the cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours 77 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 23 Brake Fluid Inspect the brake system routinely Inspect the level of the brake fluid before each operation WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown See page 53 for fluid recommendations 1 Position the vehicle on a level Maximum
61. her follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid d direction of D a RA ROME ra CIty S Ta M C Coec S AS TEC d 33 OPERATION Driving Uphill Whenever traveling uphill follow these pre cautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 15 maximum 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 7 Never go over the crest of a hill at high speed An obstacle a sharp 34 drop or another vehicle or person could be on the other side of the hill OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overtu
62. ications lluss 98 Polaris Products Ls 100 Troubleshooting e 101 Declaration of Conformity 105 Warranty ia cri rump eRe eee es 106 Maintenance Log seee 112 INDOX viet eee eet eee MEE eae ae 115 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as mot
63. in PARK 3 Stop the engine 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the frame 6 Remove the wheel nuts and washers Remove the wheel Wheel Installation Placethe transmission in PARK 2 Place the wheel in the Ont correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can d adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 3 Attach the wheel nuts and washers and finger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 81 82 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps
64. in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 90 Polaris recommends maintaining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 100 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will Lower Upper deteriorate rapidly Check the bat Mark Mark tery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 89 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 87 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 88 Make sure the positive terminal is toward the driver s side of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions be
65. k at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 91 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Ol
66. l 4 Add the recommended oll as needed 5 Reinstall the fill plug Torque to specification Fill Plug 59 MAINTENANCE Gearcases Transmission Main Gearcase Oil Change The drain plug is located on the bottom of the transmission Access the drain plug through the drain hole in the skid plate Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants capacities and torque specifications 1 1 96 nO tA Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Drain the oil Wipe the magnetic end of the drain Drain Plug plug clean to remove accumu lated metallic filings After the oil has drained completely install a new sealing washer Reinstall the drain plug Torque to specification Add the recommended oil as needed Do not overfill Reinstall the fill plug Torque to specification Check for leaks 10 Dispose of used oil properly 60 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of Polaris products Oil Check The front gearcase fill plug is located on the right side of the front gearc
67. lways follow these precautions when tow ing OPERATION 1 Never load more than 150 lbs 68 1 kg tongue weight on the tow ing bracket 2 Do not operate the vehicle faster than 10 mph 16 km h when tow ing See page 40 Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts begin ning on page 98 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER 400 1000 Ibs 850 Ibs 150 Ibs 10 mph HO 454 kg 386 kg 68 1 kg 16 kph Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 43 OPERATION Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use 44 OPERATION All Wheel Drive AWD Press the top
68. ly 38 OPERATION Parking on an Incline 15 maximum Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Block the rear wheels on the downhill side 39 OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off cente
69. mpletely 2 Presson the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re famil iar with the controls Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking 31 OPERATION Driving Procedure 32 Wear a helmet and eye protection Sit in the driver s seat and fasten the seat belt Start the engine and allow it to warm up Apply the service brakes and shift the transmission into gear Check your surroundings and determine your path of travel Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a passenger to ride in the cargo box OPERATION Driving On Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weat
70. n PARK Stop the engine Secure the fuel cap oil cap and seat Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Remove the key to prevent loss during transporting 97 SPECIFICATIONS RANGER 400 HO Maximum Weight Capacity 1000 Ibs 454 kg includes weight of operator passenger cargo accessories Dry Weight 1050 lbs 476 kg Fuel Capacity 8 8 gal 33 3 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 25 qts 2 41 Overall Length 108 in 274 3 cm Overall Width 56 5 in 143 5 cm Overall Height 73 in 185 cm Wheelbase 72 in 183 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacity 1250 lbs 567 kg Max Cargo Box Load 500 Ibs 227 kg Engine 4 valve 4 stroke single cylinder with counter balance Front Suspension Lubrication System Dry Sump Cooling Liquid Engine Oil OW 40 Displacement 455 cc Bore x Stroke mm 87 9x 75 Pilot Jet 42 5 Main Jet 150 Needle Jet P 6 829 Jet Needle 4IB33 Air Screw 215 Alternator Output 250 W Compression Ratio 9 7 1 Starting System Electric Carburetor 34 mm Ignition System CDI Ignition Timing 30 5000 RPM Spark Plug NGK BKR6E
71. n Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline Heed the gasoline warnings on page 15 Check the oil level See page 55 Add the recommended oil as needed to maintain the oil level between the safe and add marks Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 29 Pull only light loads During the break in period change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 28 OPERATION Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi tion before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Check length of belt for damage check latches for proper operation Item Remarks Page Brake system pedal travel Ensure
72. n the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never go under the vehicle while it s inclined 74 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrestor clean out plug located on the bottom of the muf fler 2 Place the transmission in Clean Out PARK Plug 3 Start the engine d 4 Purge accumulated car bon from the system by Exhaust Outlet momentarily revving the engine several times 5 Ifcarbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine several more times 6 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels 7 Repeat steps 4 and 5 until no more particles are expelled when the engine is revved 8 Stop the engine Allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 75 MAINTENANCE Throttle System AWARNING Failure to
73. ng pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 69 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 27 and 68 101 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low batterv voltage Solution Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid conn
74. of the rocker switch to engage All Wheel Drive AWD The illuminated amber AWD switch indicates that the vehicle is in AWD When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following proce dure to unlock the front gearcase
75. ome on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb Indicator Lamp Replacement 1 Lift the hood Release 2 Reach in behind the console Tab panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp Using a screwdriver rotate the lamp 1 4 turn clockwise to seat it 7 Snap the assembly back into the console panel Reconnect the har ness 8 Close the hood 85 MAINTENANCE Battery AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires
76. one year limited warranty on the final drive chain if equipped for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not co
77. orcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Key Number VIN Vehicle Model Number Frame VIN Engine Serial Number label on side of engine Key Number SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any o
78. ranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDI
79. reases your Warnin f chance of severe injury or death 9 Shift Caution NEVER operate this vehicle if vou are under age 16 and NEVER operate this vehicle without a valid driver s license 7175566 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle APPLV BRAKE TO START When this vehicle is not in operation or unattended place shift in the park position 7176170 Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury Clutch Cover or death Warning 7175488 SAFETY Safety Labels and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs e On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With more than ONE passenger or a passenger under age twelve or who can not comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover coul
80. red loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 40 OPERATION Hauling Cargo The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities Model Maximum Capacities Cargo Box Level Ground RANGER 400 HO 1000 Ibs 454 kg 500 Ibs 227 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box A passengers must always ride in the cab wit
81. rn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 15 maximum 2 Drive straight down hill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel 15 maximum straight downhill when possible 3 Slow down 4 Apply the brakes slightly to aid in slowing 35 OPERATION Driving Through Water Your Polaris RANGER can operate through water up to a maximum rec ommended depth equal to the floorboards NOTICE Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 70 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles ee 4 Avoid operating Z Z Floorboard HR through deep or fast feret er UT im
82. rrect color See page 62 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat to access the engine compartment 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation Torque to specifi cation 62 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 63 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radia tor filler neck radiator pressure cap and connecting hose As coolant operating temperat
83. s vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Always make sure the seat belts are secured for both the operator and passenger before riding Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while operating this vehicle 14 SAFETY Operator Safety Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Remove flammable material containers from box before filling Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately w
84. surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 Ifthe fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Minimum 78 Brakes Brake Inspection 1 2 Steering Wheel Inspection Check the brake svstem for fluid leaks Check the brake pedal for excessive travel or a spongv feel Check the friction pads for wear damage and looseness Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm MAINTENANCE Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 48 1 2 3 4 Position the vehicle on a level surface Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an autho rized Polaris dealer 79 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus pension if necessary 1 Remove the top shock mounting bolts from the inside mounting holes 2 Reposition th
85. the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Throttle Push the pedal down to increase Brake reel ge engine speed Spring pressure returns the pedal to the rest posi tion when released Always check that the throttle pedal returns nor mally before starting the engine Make sure there s adequate throt tle pedal freeplay See page 77 for throttle pedal adjustment proce dures 23 FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three point lap and diagonal seat belts for the operator and passenger Always make sure the seat belts are secured for all rid ers before operating The center of the seat is NOT equipped with a seat belt Never allow a passenger to ride between the operator and passen ger seats WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diago nally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks Release the strap it will self tighten d 4 Torelease the seat belt press the square red button in the buckle s cent
86. tional caution when operating on slippery surfaces 16 SAFETY Operator Safety Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 34 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water Unauthorized Use of the Vehicle Leaving the keys in t
87. tive emission control system 110 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage
88. tops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use addi
89. ure increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as rec ommended by adding coolant to the overflow bottle 64 MAINTENANCE Cooling System Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 100 for the part numbers of Polaris prod ucts Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out lined in the P
90. vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS THE WAY OUT and RANGER are registered trademarks of Polaris Indus tries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 RANGER 400 HO Owner s Manual P N 9922123 2 TABLE OF CONTENTS Introduction usum tee Sere bb EIL ep ERES 4 Safety sisi E V ee SS Se REE et eee 7 Features and Controls 18 Operation ssi E bb EUER Ee 27 Emission Control Systems 47 Maintenance lseeeslesee 48 Specif
91. ver any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps 106 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from war

maintenance

Contents

Download Pdf Manuals

Related Search

Related Contents